Toshiba RAV-GP801AT-TR Service Manual
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Toshiba RAV-GP801AT-TR Service Manual

Toshiba RAV-GP801AT-TR Service Manual

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AIR CONDITIONER (SPLIT TYPE)
SERVICE MANUAL
OUTDOOR UNIT
<SUPER DIGITAL INVERTER>
RAV-GP801AT-E
RAV-GP1101AT-E
RAV-GP1401AT-E
RAV-GP1401AT-E1
RAV-GP801ATJ-E
RAV-GP1101ATJ-E
RAV-GP1401ATJ-E
RAV-GP1401ATJ-E1
Revision 1: Sep., 2019
Revision 2: Jul., 2021
Revision 3: Apr., 2023
Revision 4: May, 2024
RAV-GP801AT-TR
RAV-GP1101AT-TR
RAV-GP1401AT-TR
RAV-GP1401AT-TR1
PRINTED IN JAPAN, Feb., 2018,
FILE No. A10-1809
TOMO

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Summary of Contents for Toshiba RAV-GP801AT-TR

  • Page 1 FILE No. A10-1809 Revision 1: Sep., 2019 Revision 2: Jul., 2021 Revision 3: Apr., 2023 Revision 4: May, 2024 AIR CONDITIONER (SPLIT TYPE) SERVICE MANUAL OUTDOOR UNIT <SUPER DIGITAL INVERTER> RAV-GP801AT-E RAV-GP801AT-TR RAV-GP1101AT-E RAV-GP1101AT-TR RAV-GP1401AT-E RAV-GP1401AT-TR RAV-GP1401AT-E1 RAV-GP1401AT-TR1 RAV-GP801ATJ-E RAV-GP1101ATJ-E RAV-GP1401ATJ-E RAV-GP1401ATJ-E1 PRINTED IN JAPAN, Feb., 2018,...

  • Page 2: Table Of Contents

    Original instruction (English) CONTENTS 1. SPECIFICATIONS ................ 17 1- 1. Indoor Unit .......................... 17 1- 1-1. 4-Way Smart Cassette <Single type> ................. 17 1- 1-2. 4-Way Smart Cassette <Twin type> ..................18 1- 1-3. 4-Way Cassette <Single type> .................... 19 1- 1-4.
  • Page 3 6- 7. Charging additional refrigerant ..................51 6- 7-1. [Assumed gas leak] ......................51 6- 7-2. [Limiting the additional charge] ..................51 6- 7-3. [Cautions on charging additional refrigerant] ..............51 6- 8. General safety precautions for using R32 refrigerant ........... 52 6- 8-1.

  • Page 4: Generic Denomination: Air Conditioner

    Please read carefully through these instructions that contain important information which complies with the “Machinery Directive” (Directive 2006/42/EC), and ensure that you understand them. Some of the details provided in these instructions differ from the service manual, and the instructions provided here take precedence.
  • Page 5 Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’ work clothing. In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below.

  • Page 6: Warning Indications On The Air Conditioner Unit

    Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positions If removing the label during parts replace, stick it as the original. Warning indication Description WARNING WARNING ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK HAZARD...

  • Page 7: Precaution For Safety

    Precaution for Safety The appliance shall be installed in accordance with national wiring regulations. Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position.
  • Page 8 WARNING Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions. Only qualified service person (∗1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.
  • Page 9 WARNING If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, wear insulated heat-resistant gloves, insulated boots and insulated work overalls, and take care to avoid touching any live parts.
  • Page 10 WARNING The refrigerant used by this air conditioner is the R32. Check the used refrigerant name and use tools and materials of the parts which match with it. For the products which use R32 refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see.
  • Page 11 WARNING When the refrigerant gas leaks, find out the leaked position and repair it surely. If the leaked position cannot be found out and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. When gas touches to fire such as fan heater, stove or cocking stove, it may generate noxious gases, causing a fire though the refrigerant gas itself is innocuous.
  • Page 12 WARNING Only a qualified installer (∗1) or qualified service person (∗1) is allowed to install the air conditioner. If the air conditioner is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result. Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner.

  • Page 13: Declaration Of Conformity / Manufacturer

    Generic Denomination: Air Conditioner Model/type: RAV-GP801AT-E, RAV-GP1101AT-E, RAV-GP1401AT-E, RAV-GP1401AT-E1 RAV-GP801ATJ-E, RAV-GP1101ATJ-E , RAV-GP1401ATJ-E, RAV-GP1401ATJ-E1 RAV-GP801AT-TR, RAV-GP1101AT-TR, RAV-GP1401AT-TR, RAV-GP1401AT-TR1 Commercial name: Super Digital Inverter Series Air Conditioner Complies with the provisions of the “Machinery Directive” (Directive 2006/42/EC) and the regulations transposing into national law Note: This declaration becomes invalid if technical or operational modifications are introduced without the manufacturer’s consent.
  • Page 14 Refrigerant R32 This air conditioner adopts a new HFC type refrigerant (R32) which does not deplete the ozone layer. 1. Safety Caution Concerned to Refrigerant R32 Be sure that water, dust, the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with refrigerant R32 during installation work or service work.

  • Page 15: Pipe Materials

    <Caution items> 1) The opposite side dimension of the air-conditioner’s flared nut using R32 and the shape of the charge port are the same as those of R410A. 2) Be careful not to charge refrigerant by mistake. Should the different type of refrigerant mix in, be sure to recharge the refrigerant 3) Do not mix the other refrigerant or refrigerating oil with the refrigerant.

  • Page 16: Specification

    4. Tools : R410A tools available : Partly unavailable, : R410A tools unavailable Installation/service tools Applicability to R32 air Applicability to R22 air conditioner or not conditioner or not Tools / Equipment specification 1 Flare tool Clutch type Pipe flaring Copper pipe gauge for Flaring by —...

  • Page 17: Specifications

    1. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Smart Cassette <Single type> Indoor unit RAV-GM 801UT-E 1101UT-E 1401UT-E Model Outdoor unit RAV-GP 801AT-E 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 6.70-6.14 9.09-8.33...

  • Page 18: 4-Way Smart Cassette

    1-1-2. 4-Way Smart Cassette <Twin type> Indoor unit 1 RAV-GM 561UT-E 801UT-E Model Indoor unit 2 RAV-GM 561UT-E 801UT-E Outdoor unit RAV-GP 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 9.09-8.33 13.92-12.76...

  • Page 19: 4-Way Cassette

    1-1-3. 4-Way Cassette <Single type> Indoor unit RAV-RM 801UTP-E 1101UTP-E 1401UTP-E Model Outdoor unit RAV-GP 801AT-E 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 7.72-7.08 10.19-9.34 15.12-13.86 Power consumption (kW) 1.58...

  • Page 20: 4-Way Cassette

    1-1-4. 4-Way Cassette <Twin type> Indoor unit 1 RAV-RM 561UTP-E 801UTP-E Model Indoor unit 2 RAV-RM 561UTP-E 801UTP-E Outdoor unit RAV-GP 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 10.19-9.34 15.12-13.86 Power consumption...

  • Page 21: Compact 4-Way Cassette

    1-1-5. Compact 4-Way Cassette <Twin type> Indoor unit 1 RAV-RM 401MUT-E 561MUT-E Model Indoor unit 2 RAV-RM 401MUT-E 561MUT-E Outdoor unit RAV-GP 801AT-E 1101AT-E Cooling capacity (kW) 10.0 Heating capacity (kW) 11.2 Power supply 1phase 220-240V/50Hz 1phase 220-240V/50Hz Indoor unit Cooling Running current 8.46-7.75 11.44-10.48...

  • Page 22: Slim Duct

    1-1-6. Slim Duct <Twin type> Indoor unit 1 RAV-RM 401SDT-E 561SDT-E Model Indoor unit 2 RAV-RM 401SDT-E 561SDT-E Outdoor unit RAV-GP 801AT-E 1101AT-E Cooling capacity (kW) 10.0 Heating capacity (kW) 11.2 Power supply 1phase 220-240V/50Hz 1phase 220-240V/50Hz Indoor unit Cooling Running current 9.14-8.38 12.25-11.23 Power consumption...

  • Page 23: Duct

    1-1-7. Duct <Single type> Indoor unit RAV-RM 801BTP-E 1101BTP-E 1401BTP-E Model Outdoor unit RAV-GP 801AT-E 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 7.97-7.30 11.48-10.53 17.08-15.66 Power consumption (kW) 1.63 2.40...

  • Page 24: Duct

    1-1-8. Duct <Twin type> Indoor unit 1 RAV-RM 561BTP-E 801BTP-E Model Indoor unit 2 RAV-RM 561BTP-E 801BTP-E Outdoor unit RAV-GP 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 11.48-10.53 17.08-15.66 Power consumption...

  • Page 25: Ceiling

    1-1-9. Ceiling <Single type> Indoor unit RAV-RM 801CTP-E 1101CTP-E 1401CTP-E Model Outdoor unit RAV-GP 801AT-E 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 7.82-7.17 10.67-9.78 17.13-15.70 Power consumption (kW) 1.60 2.23...

  • Page 26: Ceiling

    1-1-10. Ceiling <Twin type> Indoor unit 1 RAV-RM 401CTP-E 561CTP-E 801CTP-E Model Indoor unit 2 RAV-RM 401CTP-E 561CTP-E 801CTP-E Outdoor unit RAV-GP 801AT-E 1101AT-E 1401AT-E/E1 Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1phase 220-240V/50Hz Indoor unit Cooling Running current 7.82-7.17 10.67-9.78...

  • Page 27: Floor Standing

    1-1-11. Floor standing <Single type> Indoor Unit RAV-RM 801FT-EN/ES 1101FT-EN/ES 1401FT-EN/ES 1401FT-EN/ES Model Outdoor Unit RAV-GP 801AT-E 1101AT-E 1401AT-E 1401AT-E1 Cooling capacity (kW) 10.0 12.5 12.3 Heating capacity (kW) 11.2 14.0 13.2 Power supply 1phase 220-240V/50Hz Indoor Unit Cooling Running current 9.14-9.97 10.48-11.44 15.28-16.67...

  • Page 28: Floor Standing

    1-1-12. Floor standing <Twin type> Indoor unit 1 RAV-RM 561FT-EN/ES 801FT-EN/ES 801FT-EN/ES Model Indoor unit 2 RAV-RM 561FT-EN/ES 801FT-EN/ES 801FT-EN/ES Outdoor Unit RAV-GP 1101AT-E 1401AT-E 1401AT-E1 Cooling capacity (kW) 10.0 12.5 12.5 Heating capacity (kW) 11.2 14.0 14.0 Power supply 1phase 220-240V/50Hz Indoor Unit Cooling...

  • Page 29: Outdoor Unit

    1-2. Outdoor Unit Model Outdoor unit RAV-GP 801AT-E 1101AT-E 1401AT-E/E1 1 phase 220-240 50Hz Power supply (Power exclusive to outdoor is required) Type Hermetic compressor Compressor Motor (kW) 2.00 3.75 3.75 Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Pipe Height Outdoor lower...

  • Page 30: Operation Characteristic Curve

    1-3. Operation Characteristic Curve • Operation characteristic curve GP801 <Cooling> <Heating> 110% 130% 105% 120% 100% 110% 100% GP801 GP801 • Conditions • Conditions Indoor:DB27˚C/WB19˚C Indoor:DB20˚C Indoor air flow:High Indoor air flow:High Pipe length:7.5m Pipe length:7.5m 230V ,50Hz(1phase) 230V ,50Hz(1phase) -27 -24 -21 -18 -15 -12 -9 -6 -3 0 9 12 Outdoor temperature (˚C)
  • Page 31 • Capacity variation ratio according to temperature GP801 <Cooling> <Heating> GP801 GP801 GP801 GP801 GP801 GP801 • Conditions • Conditions Indoor:DB27˚C/WB19˚C Indoor:DB20˚C Outdoor:DB35˚C Outdoor:DB 7˚C/WB6˚C Indoor air flow:High Indoor air flow:High Pipe length:7.5m Pipe length:7.5m 230V ,50Hz(1phase) 230V ,50Hz(1phase) 90 100 10 20 30 40 50 60 70 80 90 100 110 Compressor speed (rps) Compressor speed (rps)

  • Page 32: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. RAV-GP801AT* ­ ­ ‒ 32 ‒ – 32 –...

  • Page 33: Rav-Gp1101At*, Gp1401At

    2-2. RAV-GP1101AT*, GP1401AT* ­ ­ ‒ 33 ‒ – 33 –...

  • Page 34: Branch Pipe

    2-3. Branch pipe RBC-TWP31-E (Simultaneous Twin) Unit: mm DIA D DIA D DIA C Model (RBC-) DIA C DIA D Liquid side TWP31-E Gas side 15.9 12.7 * DIA C and DIA D indicate the connecting pipe diameter. Liquid side DIA 9.6 Notch Notch...
  • Page 35 RBC-TWP50E2 (Simultaneous Twin) Unit: mm DIA C DIA D DIA D Model (RBC-) DIA C DIA D Liquid side TWP50E2 Gas side 15.9 15.9 * DIA C and DIA D indicate the connecting pipe diameter. ­ ­ ‒ 35 ‒ –...

  • Page 36: Outdoor Unit Refrigeranting Cycle Diagram

    3. OUTDOOR UNIT REFRIGERANTING CYCLE DIAGRAM GP801 Pulse motor valve TS sensor Fan motor Capillary tube TO sensor Outdoor heat exchanger TL sensor 4-way valve High-pressure switch Automatic restoration TD sensor OFF:4.15Mpa ON :3.2MPa sensor Distributor Strainer DIA 12.7 Liquid pipe DIA 9.5 Packed valve Accumulator...
  • Page 37 GP1101/1401 Pulse motor valve TS sensor Fan motor Capillary tube 4-way valve TO sensor Strainer DIA 12.7 Outdoor heat exchanger Check joint Cooling : High pressure TL sensor Heating : Low pressure High-pressure switch Automatic restoration TD sensor OFF:4.15Mpa ON :3.2MPa sensor Liquid tank (500cc)
  • Page 38 RAV-GP801 series Pressure Pipe surface temperature (˚C) Compressor Indoor/outdoor Indoor heat Outdoor heat Indoor drive revolution temp.condition (Mpa) (kg/cm g) Discharge Suction exchanger exchanger frequency (rps) (TD) (TS) (TC) (TL) (TE) indoor outdoor 46.8 43.0 48.0 HIGH Standard 27.9 11.0 71.7 15.6 14.0...

  • Page 39: Wiring Diagram

    4. WIRING DIAGRAM 4-1. RAV-GP801AT* ­ ­ ‒ 39 ‒ – 38 –...

  • Page 40: Rav-Gp1101At*, Gp1401At

    4-2. RAV-GP1101AT*, GP1401AT* ­ ­ ‒ 40 ‒ – 39 –...

  • Page 41: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit RAV-GP801AT* Parts name Type Specifications Compressor NX220A1F-20N — Outdoor fan motor ICF-280-A60-1 DC280V, 60W STF-H01AZ1724A1 DC12V 4-way valve coil PMV coil UKV-A040 DC12V OFF:4.15MPa High pressure switch ACB-4UB83W Compressor thermostat US-622 OFF:125 ± 4˚C , ON:90 ± 5˚C Reactor CH-101 10mH, 20A...

  • Page 42: Refrigerant R32

    6. REFRIGERANT R32 This air conditioner adopts the R32 refrigerant which according to the installation manual. does not damage the ozone layer. Improper installation may cause refrigeration The working pressure of the new refrigerant R32 is trouble, water leakage, electric shock, fire, etc. 1.6 times higher than conventional refrigerant (R22).

  • Page 43: Processing Of Piping Materials

    Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A or R32 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 2. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for piping whose outer diameter exceeds 20 mm.
  • Page 44 c) Insertion of Flare Nut d) Flare Processing Outer diameter Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A / R32 or conventional flare tool.
  • Page 45 Fig. 6-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench.

  • Page 46: Tools

    6-3. Tools 6-3-1. Required Tools Refer to the “4. Tools” (Page 16) 6-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment.

  • Page 47: Brazing Of Pipes

    NOTE 1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. R32 refrigerant is a Single-component refrigerant that does not change its composition. Although it is possible to charge the refrigerant with either liquid or gas, charge it with liquid.

  • Page 48: Brazing

    2. Characteristics required for flux 6-5-3. Brazing • Activated temperature of flux coincides with the As brazing work requires sophisticated techniques, brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is In order to prevent the oxide film from occurring in the hard to carbonize.

  • Page 49: Instructions For Re-Use Piping Of R22 Or R407C

    Operation System case. • In the concurrent twin system, when TOSHIBA- ∗ ∗ ∗ ∗ ∗ Pipe diameter and thickness (mm) specified branching pipe is used, it can be reused.

  • Page 50: Final Installation Checks

    6-6-5. Final Installation Checks Existing pipes: Cannot be used. Are there scratches or dents on the existing pipes? • Use new pipes. Is it possible to operate the existing air conditioner? • After the existing air conditioner is operated in cooling mode for approx.

  • Page 51: Handling Of Existing Pipe

    6-6-6. Handling of Existing Pipe 6-6-7. Recovering Refrigerant When using the existing pipe, carefully check it for the Use the refrigerant recovery equipment to recover the following: refrigerant. • Wall thickness (within the specified range) 6-7. Charging additional refrigerant • Scratches and dents •...

  • Page 52: General Safety Precautions For Using R32 Refrigerant

    6-8. General safety precautions for using R32 refrigerant 6-8-1. Recovery • Before carrying out this procedure, it is essential that the technician is completely familiar with the • When removing refrigerant from a system, either for equipment and all its details. Only a qualified servicing or decommissioning, it is recommended installer (∗1) or qualified service person (∗1) is good practice that all refrigerants are removed...

  • Page 53: Circuit Configuration And Control Specifications

    7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1705 CN807 (WHT) Connector for temperature sensor CN805 (BLU) Connector for TL CN604 (WHT), TD CN603 (WHT), TO CN602 (YEL) Connector for Display P.C. board MCC-1646 TE CN601 (WHT), TS CN600 (WHT) Option P.C.

  • Page 54: Outline Of Main Controls

    7-2. Outline of Main Controls 1. PMV (Pulse Motor Valve) control 1) The aperture of the PMV is controlled between 30 to 500 pulses during operation. 2) During cooling operations, the PMV aperture is controlled by the temperature difference between TS sensor and TC sensor, the temperature difference in cooling operations is usually controlled using a 1 to 4K target value.

  • Page 55: Cooling Fan Control

    3. Outdoor fan revolution number control Control of fan revolution number and the fan taps in this unit are shown below. Fan Taps Revolution number Allocation [rpm] GP80 GP110 Upper Fan GP140 Lower Fan 3-1. Cooling fan control 1) Cooling operations of the outdoor fan are controlled by a TL sensor, TO sensor and the compressor revolution number.
  • Page 56 3-2. Heating fan control 1) Heating operations of the outdoor fan are controlled by a TE sensor, TO sensor and the compressor revolution number. (Control from a minimum W1 to a maximum is performed according to the table below). 2) Operation is fixed for 3 minutes after start up by a maximum fan tap corresponding to the zones in the table below.

  • Page 57: Defrost Control

    4. Defrost control 1) During heating operations, defrost operations are performed when the temperature from the TE sensor satisfies any of the conditions in the A to D zones. 2) During defrosting operations, defrost will be terminated if the temperature from the TE sensor continues at 12°C or higher for 3 seconds or if the temperature is 7°C ≤...

  • Page 58: High-Pressure Switch/Compressor Case Thermostat Control

    7. Heat sink temperature detection control 1) IGBT overheating prevention is protective control performed by a thermistor (TH sensor) in proximity to IGBT. 2) When a temperature of TH < 90°C is detected, the fan tap is moved by 1 step up. Thereafter step-up is performed at a rate of +1 tap/5 seconds until a maximum fan tap is reached.

  • Page 59: Coil Heating Control

    12. Coil heating control 1) This control has the function of heating the compressor by applying a current to the compressor when not operating instead using a case heater. This control is for the purpose of preventing stagnation of the refrigerant inside the compressor. 2) Malfunction in the compressor may result if a current is not applied for a specified time before a test run after installation as was previously the case.

  • Page 60: Troubleshooting

    8. TROUBLESHOOTING 8-1. Summary of Troubleshooting <Wired remote controller type> 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, long-nose pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal.
  • Page 61 <Wireless remote controller type> 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, long-nose pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1. Compressor does not operate. •...

  • Page 62: Troubleshooting

    8-2. Troubleshooting 8-2-1. Outline of judgment The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method. Method to judge the troubled position by flashing indication on the display part of the indoor unit (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
  • Page 63 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready Heat exchanger sensor (TCJ) trouble Heat exchanger sensor (TC) trouble Indoor unit sensor trouble Room air temperature sensor (TA) trouble Alternate flash Discharge temp. sensor (TD) trouble Temp. sensor (TE) trouble Operation Timer Ready Temp.

  • Page 64: Others (Other Than Check Code)

    8-2-2. Others (Other than Check Code) Lamp indication Check code Cause of trouble occurrence Operation Timer Ready — During test run Simultaneous flash Operation Timer Ready Disagreement of cool/heat — (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model) Alternate flash ­...

  • Page 65: Monitor Function Of Remote Controller Switch

    8-2-3. Monitor Function of Remote Controller Switch Calling of sensor temperature display <Contents> Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. <Procedure> Push buttons simultaneously for 4 seconds to call the service monitor mode.

  • Page 66: Check Code List (Outdoor)

    ­ ­ ‒ 66 ‒ – 65 –...
  • Page 67 ­ ­ ‒ 67 ‒ – 66 –...
  • Page 68 Failure mode detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of Cause of operation Condition code air conditioner 1. Check cables of remote controller and communication adapters. No communication from remote Displayed when Stop controller (including wireless) and •...
  • Page 69 Failure mode detected by outdoor unit Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit Disconnection, short-circuit of Displayed when 1. Check discharge temp. sensor (TD). Stop discharge temp. sensor (TD) trouble is detected 2.
  • Page 70 Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit Discharge temp. trouble 1. Check refrigerating cycle (Gas leak) Displayed when ∗ Discharge temp. (TD) over Stop 2. Trouble of electronic expansion valve trouble is detected specified value was detected.
  • Page 71 Failure mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner Power supply trouble of remote controller, Indoor EEPROM trouble Not displayed 1. Check remote controller inter-unit wiring. No communication with header indoor unit at all 2.

  • Page 72: Diagnostic Procedure For Each Check Code (Outdoor Unit)

    8-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board to narrow the contents to be confirmed. 3) The check code on the remote controller is displayed only when the same trouble occurred continuously by multiple times while LED of the outdoor P.C.
  • Page 73 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] [Discharge temp. sensor (TD) trouble] Is connection of CN603 correct? Correct connector. Is resistance value of TD sensor correct? Replace TD sensor Replace outdoor P.C.
  • Page 74 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F15] [Miswiring of heat exchanger sensor (TE, TS)] Is mounting status of Correct sensor mounting. TE and TS sensors correct? Is connection of CN600 correct? Correct connector.
  • Page 75 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H02] [Compressor lock] Is power supply voltage normal? Correct power supply line. AC198 to 264V Is wire connection correct? Compressor lead Check wire connection (P.C.
  • Page 76 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [L10] [Heat sink temp. sensor (TH) trouble] Cut jumper line according to the explanation sheet packaged with the service P.C. board. [L29] [Communication trouble MCUs] Replace outdoor P.C.board [P03] [Discharge temp.
  • Page 77 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P07] [Heat sink overheat trouble] Are radiation grease properly applied? Is the screw stop of the motor drive Apply radiation grease element IC200 on the outdoor P.C. board, to objective, retightening the sub heat sink, and the diode bridge of screw...
  • Page 78 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P19] [4-way valve inverse trouble] Does 4-way valve Is the coil work correctly? resistance Replace (Check pipe temp. etc. value of 4-way 4-way valve coil in cooling/heating valve normal? operation.)
  • Page 79 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] [High pressure protective operation] [P04] Is service valve Open service valve fully. fully opened? Reset the power supply and then perform test run Cooling season matching to the season.
  • Page 80 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] [Fan system trouble] Is power supply voltage normal? Check wiring construction. AC198 to 264V Ask repair of power supply. Rotate shaft of the fan motor by hands during power-OFF.
  • Page 81 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P26] [Short-circuit of compressor drive element] Are connections of compressor lead and reactor correct? Correct wiring. (Check referring to the Wiring diagram.) Does the same trouble occur in Replace outdoor operation without compressor lead? P.C.

  • Page 82: Temperature Sensor

    Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (k Ω) Resistance value (k Ω) Temperature Temperature (˚C) (˚C) (Minimum value) (Standard value) (Maximum value) (Minimum value) (Standard value) (Maximum value) 32.33 33.80...

  • Page 83: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Check code History <Contents> The trouble contents in the past can be called. <Procedure> TEMP. ON / OFF Push buttons simultaneously for 4 seconds or TIMER SET MODE more to call the service check mode. TIME SAVE VENT...
  • Page 84 Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way <By feed unit> <Automatic address judgment> Not normal 3 minutes elapse Gr construction check Normal ∗...

  • Page 85: Outdoor Unit

    9-2. Outdoor Unit Various status displays and operations can be accessed using the push buttons (service switches) on the outdoor display P.C. board and LED display. Service switch (SW01 and SW02) operation <GP110, GP140> SW01 SW02 (D800 to D805) <GP80> SW01 SW02 (D800 to D805)

  • Page 86: Led Display

    1. Various settings available via the outdoor unit (Existing pipe, Cooling only, Snow guard fan control, Maximum frequency change) (1) Service switch setting Enable / disable of various settings can be made using the service switches. [Method of operation] 1) Ensure the LED display shows the initial status. If not then ensure to restore the initial status. If any unclear point arises during an operation then can be return to step 1) by pushing and hold down SW01 and SW02 at the same time for 5 seconds or more to initialize the LEDs.

  • Page 87: Returning To The Factory Default Settings

    Various settings confirmation method Whether the various settings are in effect or not can be confirmed. 1) Ensure the LED display shows the initial status. If not then ensure to restore the initial status. 2) Push SW01 for at least 5 seconds. D804 will start slowly flashing. 3) Push SW01 several times until reaching the desired function on the LED display.
  • Page 88 2. Service support functions (LED display and switch operation) (1) LED display switching (SW01 and SW02 operation) (1)-1. Display switch list Service switches SW01 and SW02 can be used to change the display content of LEDs D800 to D805 on the outdoor unit.

  • Page 89: Trouble Display

    (1)-2. Trouble display Current and the latest trouble (latest and including the present trouble) can be checked using the lighting status of the LEDs D800 to D805 on the outdoor unit. (1)-2-1. Current trouble indication LED indication Wired remote Name of trouble control trouble code D800 D801 D802 D803 D804 D805 Normal...
  • Page 90 (1)-3. Sensor, current, compressor operation frequency, PMV opening indication Interface (CDB) P.C. board detected values (for example temperature and current sensor values) can be easily checked. ∗ Temperature sensors ... TD, TE, TL, TS, TO, TH, TA, TC, TCJ ∗ Current ......Current sensor (CT) value detected LED indication Temperature Compressor...
  • Page 91 (1)-4. Refrigerant leak detection function Monitors the amount of refrigerant being circulated based on the temperature sensors, compressor rotation speed, PMV opening during operation, and detects any refrigerant leaks during operation and indicates it using the LEDs on the outdoor unit. CAUTION ∗...
  • Page 92 (2) Maintenance inspections Special operations (SW01 and SW02 operations) The following special maintenance and inspection operations can be carried out using the service switches SW01 and SW02. [Method of operation] 1) Ensure the LED display shows the initial state. If not then please ensure to return it to the initial state. 2) Push and hold down SW01 for at least 5 seconds.
  • Page 93 3. Outdoor application operation Optional connector kit (TCB-PCOS1E2) (1) Peak-cut control • Saves the power of the outdoor unit by the external peak-cut signal to suppress temporary peak power dissipation. • The power saving can be switched to three levels: 75%, 50%, and operation stop. (2) Night operation •...

  • Page 94: Address Setup

    10. ADDRESS SETUP 10-1. Address Setup Procedure When an outdoor unit and an indoor unit are connected, or when an outdoor unit is connected to each indoor unit respectively in the group operation even if multiple refrigerant lines are provided, the automatic address setup completes with power-ON of the outdoor unit.

  • Page 95: Address Setup & Group Control

    10-2. Address Setup & Group Control <Definitions of terms> Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/from...

  • Page 96: System Configuration

    10-2-1. System Configuration 1. Single Outdoor Indoor (Master/Header) Individual Remote controller 2. Twin Master/Header Sub/Follower 3. Single group operation Sub/Header Master/Header Sub/Header Sub/Header Sub/Header (Max. : 8 units) • Each indoor unit controls the outdoor unit individually. 4. Multiple groups operation (Single, Twin operation) Sub/Header Sub/Header Sub/Follower...

  • Page 97: Automatic Address Example From Unset Address (No Miswiring)

    10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1. Single 2. Twin Individual Master/Header Sub/Follower Only turning on source power supply (Automatic completion) 2. Single group operation (Multiple outdoor units = Multiple indoor units only with serial communication) Sub/Header Master/Header Sub/Header...

  • Page 98: Address Setup (Manual Setting From Remote Controller)

    10-4. Address Setup (Manual setting from remote controller) (Example of 2-lines wiring) In case that addresses of the indoor units will be (Solid line: Wiring, Broken line: Refrigerant pipe) determined prior to piping work after wiring work Outdoor Outdoor • Set an indoor unit per a remote controller. 1 2 3 1 2 3 •...

  • Page 99: Confirmation Of Indoor Unit No. Position

    10-5. Confirmation of Indoor Unit No. Position 1. To know the indoor unit addresses though position of the indoor unit body is recognized • In case of individual operation (Wired remote controller : indoor unit = 1 : 1) (Follow to the procedure during operation) <Procedure>...
  • Page 100 <Maintenance/Check list> Aiming in environmental preservation, it is strictly recommended to clean and maintain the indoor/outdoor units of the operating air conditioning system regularly to secure effective operation of the air conditioner. It is also recommended to maintain the units once a year regularly when operating the air conditioner for a long time.

  • Page 101: Replacement Of The Service P.c. Board

    11. REPLACEMENT OF THE SERVICE P.C. BOARD 1. DN setting the jumper wires and DIP switches Part name Function Setting Jumper J800 ~ J804 Model switching Cut these jumper wires according to the wire following table. J805 ~ J807 Settings Set these jumper wires same as the settings of the P.C.

  • Page 102: How To Exchange Compressor

    12. HOW TO EXCHANGE COMPRESSOR 12-1. Exchanging Procedure of Compressor (Outline) START Open PMV forcedly and then recover refrigerant Has refrigerant recovery work been done? using a refrigerant recovery unit. Turn off the circuit breaker. Never recover the refrigerant to the outdoor unit. •...

  • Page 103: Detachments

    13. DETACHMENTS 13-1. RAV-GP801AT* No. Part name Procedure Remarks WARNING Common Front panel procedures Stop operation of the air conditioner and turn off breaker switch. Front panel Top cover CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc. Left cl Left cla a w w Left claw...
  • Page 104 No. Part name Procedure Remarks 1. Detachment Side Side cabinet (left) cabinet 1) Following to work of Detachment of (left) 2) Remove the side cabinet (left) and base plate screws. (2 pcs, DIA 4 ×10 hexagon screws) 3) Slide the side cabinet (left) downwards and remove it. 2.
  • Page 105 No. Part name Procedure Remarks 1. Detachment (Control P.C. board) Electrical part 1) Following to work of Detachment of (Control P.C. board ) WARNING Do not disassemble the inverter for a minute after the power is turned off since there is a risk of electric shock. *1.Ensure to bundle again with a commercially available Inverter cover Inverter cover...
  • Page 106 No. Part name Procedure Remarks Electrical 14) Remove a screw fixing heat sink duct and inverter box. Inverter box Inverter box Inverter box part (ST3T DIA 4×8, 2 pcs) (Continued) Heat sink duct and Heat sink duct and Heat sink duct and Inverter box fixing Inverter box fixing Inverter box fixing...
  • Page 107 No. Part name Procedure Remarks 3. Detachment (Reactor) Electric part 1) Following to work of Detachment of Reactor (Reactor) 2) Remove the connector of the reactor lead wire connected to the reactor. (2 positions) 3) Remove the connector. Reactor lead × 2 ( DIA 4 ST3T, 2 pcs,) 4.
  • Page 108 No. Part name Procedure Remarks Fan motor 8) Cut the binding band for the air duct fixing fan motor (continued) and the motor base ( 2 position ). 9) Loosen the two claws on the motor base. 10) Remove the fixing screws (4 positions) while holding the fan motor so as not to fall it.
  • Page 109 No. Part name Procedure Remarks 1.Detachment Compressor WARNING compressor lead When removing the brazing part of the suction / discharge pipe of the compressor, remove the brazing part in a well- ventilated place after recovering the refrigerant. If recovery is insufficient, the refrigerant and refrigerating Pipe panel (front)) Pipe panel (front)) Pipe panel (front))
  • Page 110 No. Part name Procedure Remarks 2. Attachment Compressor Compressor lead connector Compressor lead connector Compressor lead connector 1) Attach the compressor in the reverse process of compressor “1. Detachment”. lead Ferrite core Ferrite core Ferrite core (continued) Roll the compressor lead Roll the compressor lead Roll the compressor lead •...
  • Page 111 No. Part name Procedure Remarks 1. Detachment PMV coil Bundle the all lead wires on the back face and then cut the 1) Following to work of Detachment of binding band fixing inverter box. 2) Cut the binding band (two positions) on the back surface 3) Pull the connector for PMV coil out of control P.C.
  • Page 112 No. Part name Procedure Remarks 1. Detachment Fan guard 1) Following to work of Detachment of Discharge cabinet NOTE Do the work on a cardboard or a cloth to prevent the product from being scratched. Hooking claw Hooking claw Hooking claw 2) Remove the outlet cabinet and place the fan guard side facing down.

  • Page 113: Rav-Gp1101At*, Gp1401At

    13-2. RAV-GP1101AT*, GP1401AT* No. Part name Procedure Remarks WARNING Common Front panel procedures Stop operation of the air conditioner and turn off breaker Front panel switch. Top cover CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc. Right claw Right claw Right claw...
  • Page 114 No. Part name Procedure Remarks 1. Detachment Side Side cabinet (left) cabinet 1) Following to work of Detachment of (left) 2) Remove the side cabinet (left) and base plate screws. (2 pcs, DIA 4 ×10 hexagon screws) 3) Slide the side cabinet (left) downwards and remove it. 2.
  • Page 115 No. Part name Procedure Remarks 1. Detachment (Control P.C. board) Electrical part 1) Following to work of Detachment of (Control P.C. board ) WARNING Do not disassemble the inverter for a minute after the power is turned off since there is a risk of electric shock. *1.Ensure to bundle again with a commercially available Inverter cover Inverter cover...
  • Page 116 No. Part name Procedure Remarks Electrical 14) Remove screws fixing the heat sink duct and inverter Inverter box Inverter box Inverter box part box. (Continued) (ST3T DIA 4×8, 2 pcs) Heat sink duct and Heat sink duct and Heat sink duct and Inverter box fixing Inverter box fixing Inverter box fixing...
  • Page 117 No. Part name Procedure Remarks 3. Detachment (Reactor) Electric part 1) Following to work of Detachment of Reactor (Reactor) 2) Remove the connector of the reactor lead wire connected to the reactor. (2 positions) 3) Remove the connector. Reactor lead × 2 ( DIA 4 ST3T, 2 pcs,) 4.
  • Page 118 No. Part name Procedure Remarks Fan motor 8) Cut the binding band for the air duct fixing fan motor Binding band Claw (Continued) and the motor base ( 2 position ). For upper fan motor: one at the motor base For lower fan motor: one at the motor base one at the air duct Loose the claw on the fan motor base (2 positions)
  • Page 119 No. Part name Procedure Remarks 1.Detachment Compressor WARNING compressor lead When removing the brazing part of the suction / discharge pipe of the compressor, remove the brazing part in a well- ventilated place after recovering the refrigerant. If recovery is insufficient, the refrigerant and refrigerating Pipe panel (rear) Pipe panel (rear) Pipe panel (rear)
  • Page 120 No. Part name Procedure Remarks 2. Attachment Compressor Compressor lead connector Compressor lead connector Compressor lead connector 1) Attach the compressor in the reverse process of “1. compressor Detachment”. lead Ferrite core Ferrite core Ferrite core (Continued) Roll the compressor lead Roll the compressor lead Roll the compressor lead •...
  • Page 121 No. Part name Procedure Remarks 1. Detachment PMV coil Bundle the all lead wires on 1) Following to work of Detachment of the back face and then cut the binding band fixing inverter box. 2) Cut the binding band (2 positions) on the back surface Cut the binding Cut the binding Cut the binding...
  • Page 122 No. Part name Procedure Remarks 1. Detachment Fan guard 1) Following to work of Detachment of NOTE Discharge cabinet Do the work on a cardboard or a cloth to prevent the product from being scratched. 2) Remove the outlet cabinet and place the fan guard Hooking claw Hooking claw Hooking claw...

  • Page 123: Exploded Views And Parts List

    14. EXPLODED VIEWS AND PARTS LIST 14-1. Outdoor Unit RAV-GP801AT(J)-E, RAV-GP801AT-TR 012, 013 029, 030 033, 034 031, 032 016, 017 037, 038 019, 020, 021 022, 023, 024 035, 036 ­ ­ ‒ 123 ‒ – 122 –...
  • Page 124 PANEL, SIDE 4310A165 PANEL, SIDE, LEFT 43100437 PANEL, FRONT, PIPING 4310A115 PANEL, BACK, PIPING 43107276 HANGER 43107295 HADLE, HANGER 4311M659 MARK, TOSHIBA 43122153 SUPPORTER, MOTOR 43122154 SUPPORTER, MOTOR 4312C042 MOTOR, FAN, ICF-280-A60-1 43120270 FAN, PROPELLER, PS561 43F47669 NUT, FLANGE 43197164...
  • Page 125 RAV-GP1101AT(J)-E, RAV-GP1401AT(J)-E, RAV-GP1401AT(J)-E1 RAV-GP1101AT-TR, RAV-GP1401AT-TR, RAV-GP1401AT-TR1 027, 028 031, 032 015, 016 029, 030 036, 037 018, 019, 020 021, 022, 023 034, 035 ­ ­ ‒ 125 ‒ – 124 –...
  • Page 126 PANEL, SIDE 4310A127 PANEL, SIDE, LEFT 43100437 PANEL, FRONT, PIPING 4310A115 PANEL, BACK, PIPING 43107276 HANGER 43107295 HADLE, HANGER 4311M659 MARK, TOSHIBA 43122177 SUPPORTER, MOTOR 4312C100 MOTOR, FAN, ICF-280-A100-1(A) 43120270 FAN, PROPELLER, PS561 43F47669 NUT, FLANGE 43197164 NUT, FLANGE 43141529...

  • Page 127: Inverter Assembly

    14-2. Inverter Assembly SPACER, COLLAR SPACER, BUSH PC BOARD ASSY, MCC-1705 PC BOARD ASSY, MCC-1646 FUSE(10A) SENSOR, TD HOLDER, SENSOR(TO) SENSOR, TL SENSOR, TE HOLDER, SENSOR(TD) SENSOR, TO HOLDER, SENSOR(TS) SENSOR, TS HOLDER, SENSOR(TE) TERMINAL BLACK,3P 20A TERMINAL BLACK,3P 60A Q’ty/Set RAV-GP 1101AT-E...

  • Page 128: Revision Record

    Gate City Osaki West Tower, 1-11-1 Osaki, Shinagawa-ku, Tokyo, Japan Copyright © 2024, Carrier Japan Corporation, ALL Rights Reserved. Revision record — — Feb., 2018 Revision 2 The model addition of the E1 and TR1 series All the pages Jul., 2021 Correct the mistake in the service switch Revision 3 Apr., 2023...

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